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I've been talking about this for well over a year and with the approach of Celebration 5 coming this summer, I decided I needed to revisit this.

Back in 2008, I had made an Ahsoka costume for my daughter to wear in a local Halloween parade with our group in the 501st New England Garrison. It looked pretty good but the headpiece lacked the depth I wanted and was just too heavy for her to wear. It was made with Crayola air dry clay over a chicken wire frame and finished off with latex caulking. She enjoyed portraying the character but didn't like wearing the headpiece because it was so uncomfortable. After being prodded several times to sculpt one and mold it in latex or memory foam, I've finally decided to pick the project back up again.

First stab at the costume in 2008:

My first attempt back at it was this past fall using pink foam for the base of the headpiece. For a few weeks, I thought about just carving it out of the foam itself but it just lacked the correct feel and shape. Foam alone was just too stiff. It needs to be softer.

Since that was an utter and complete failure I decided to start sculpting a base out of clay that I'd eventually pull latex or Dragon Skin casts of. I'm MUCH happier with the dimensions of this version and how it's coming out.

It's looking pretty good so far. I'm liking the basic shape... once you are happy with that, I'm sure the smoothing will come. I'd make the top of the horns much more pointed, though. The topography of Tano's head remind me of wind swept sand dunes, with 3 crisp beveled planes (center, side and back) meeting in one sharp point.

Don't know if this helps, but here is a pic of the voice actress standing next to an Ahsoka. The caption leads me to believe it is an official LFL one. Or you might check with TK-409, I believe there was an official Ahsoka at the White House with him. Might be able to find a few pics to get a feel for how LFL is portraying a non-CGI version.

Thanks for the pic, I've seen her in person actually though. She was wearing an official LFL Ahsoka costume. I actually met her the Friday morning before the White House gig when we were both in a group on the Today Show on NBC for their Halloween episode. I was in clonetrooper armor. We talked back in the green room and I got a great look at the headpiece. It was constructed out of a memory foam type material.

See, I'm not so sure about points though. If anything, I was actually thinking they were too tall. Depending upon the picture you look at, they kind of change it.

I guess I wasn't clear, I was simply referring to the shape, not size. Your horn tops are round beady things, I'm suggesting they go into crisp points. I very much agree they are to large and tall in size. I think they should be significantly lower, closer to the surface. Something like this:

Wow, nice work on your daughter's costume!
I think I met you at Dragon*Con '08. I was there with my girlfriend, who was wearing her Ahsoka costume. It was still a little rough, as we had spent the first two nights of the con still making the headpiece.
Good luck on your new headpiece, I look forward to seeing it when you're done!

Looks good so far. The one concern I have is that the base of your headpiece may end up being too narrow. Those foam heads are kinda cartoony and alien-like in that respect. It narrows dramatically toward the chin. It looks like that's what this one does, but it could be a trick of the camera angle.

Looks good so far. The one concern I have is that the base of your headpiece may end up being too narrow. Those foam heads are kinda cartoony and alien-like in that respect. It narrows dramatically toward the chin. It looks like that's what this one does, but it could be a trick of the camera angle.

Your Akul Teeth look great! And your daughter makes a great Ahsoka.

That may be a bit of my fault. I kind of encouraged Bob to err on the side of narrow since the thing will be cast out of Dragon Skin and filled with styrofoam beads and/or polyfil of some sort. My reasoning was it would be better tho have the tentacles hug the face and since the would be very flexible, any reasonable sized head could fit in it. I figured we've seen too many Ahsoka/Shaak ti/what have you type head pieces that hang way far away from the sides of the head, causing all sorts of issues with exposing the ears and hair and stuff.

I'm still agreeing with you Mark. Dragon skin is soft and the tendrils will push away from the face a bit (plus... this foam head is slightly bigger than my daughter's head already). I'm thinking it should be fine.

Goldenrod: Thanks. I had noticed that unfortunately. Should be a fairly easy fix though.